Composite body for a golf car and utility vehicle

ABSTRACT

A golf car or utility vehicle having a composite body. In some aspects of the invention, the golf car or utility vehicle has a composite body assembly that includes a front clam shell assembly and a rear shell-like body. In other aspects, the golf car or utility vehicle includes a composite body assembly having a periphery and one or more decorative body panels, the decorative body panels being recessed inwardly relative to the composite body assembly periphery to prevent impacts to the panels.

This application is a divisional of U.S. application Ser. No.10/543,182, filed Feb. 17, 2006, which was the National Stage ofInternational Application No. PCT/US04/01760, filed Jan. 23, 2004, whichclaims the benefit of U.S. Provisional Application Ser. No. 60/442,192,filed Jan. 24, 2003, the entire contents of which are incorporatedherein by reference.

BACKGROUND AND FIELD OF THE INVENTION

The invention relates to golf cars and utility vehicles, and moreparticularly, to the bodies of such golf cars or utility vehicles.

Vehicles, such as golf cars and utility vehicles, typically include aframe, a plurality of wheels rotatably mounted to the frame and a bodymounted to the frame. The body basically functions to cover or enclosevehicle components such as a motor, drive system components, a powersource (e.g., batteries or a fuel tank), axle assemblies, etc.Generally, the bodies of such vehicles are formed of numerous panels orsimilar structural members attached to the frame.

SUMMARY OF THE INVENTION

In one aspect, the present invention is a golf car comprising a frameand a composite body assembly mounted on the frame and configured toincrease rigidity of the frame. The composite body assembly includes afront body section and a rear body section. The front body sectionincludes at least two molded panels connected together so as to form aclam shell assembly, the molded panels each being formed of afiber-reinforced polymer. The rear body section is formed of a moldedfiber-reinforced polymer. In another aspect, the present invention is autility vehicle comprising the above-described elements of the golf car.

In a further aspect, the present invention is a golf car comprising ahigh-strength molded composite body assembly formed from at least onemolded fiber-reinforced polymer panel and having a periphery. Aplurality of wheels support the body for movement along the ground.Further, at least one decorative body panel is connected with thecomposite body assembly. The decorative body panel is recessed inwardlyrelative to the periphery of the composite body assembly such that thecomposite body assembly extends outwardly of the decorative body panelto prevent impact with the panel.

In yet another aspect, the present invention is a method formanufacturing a vehicle comprising the steps of: providing a frame,connecting two molded fiber-reinforced polymer panels to form a clamshell assembly, mounting the clam shell assembly to a front portion ofthe frame, and mounting a rear body section to a rear portion of theframe. The rear composite body is formed from fiber-reinforced polymerand the clam shell assembly, the rear body section and the frame forminga substantially rigid high-strength frame and body assembly.

In an even further aspect, the present invention is also a golf carcomprising a frame and a composite body assembly mounted to the frameand configured to increase rigidity of the frame. The body assemblyincludes a front body section and a rear body section. The front bodysection includes upper and lower panels connected together so as to forma generally box-like frame. Further, the rear body section includes ashell having an open lower end and at least partially bounding aninterior chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described with reference to theaccompanying drawings, which show an exemplary embodiment of the presentinvention. However, it should be noted that the invention as disclosedin the accompanying drawings is illustrated by way of example only. Thevarious elements and combinations of elements described below andillustrated in the drawings can be arranged and organized differently toresult in embodiments which are still within the spirit and scope of thepresent invention.

In the drawings, wherein like reference numeral indicate like parts:

FIG. 1 is a perspective view of a golf car or utility vehicle embodyingthe invention;

FIG. 2 is a perspective view of the golf car shown in FIG. 1 showing theframe assembly including a frame and rear body supports;

FIG. 3 is a perspective view of the golf car frame shown in FIG. 2;

FIG. 4 is a side perspective view of the golf car shown in FIG. 1illustrating a composite body assembly and frame assembly;

FIG. 5 is rear perspective view of the golf car frame, showing aninternal combustion engine and related components connected with theframe;

FIG. 6 is a front perspective view of the golf car composite bodyassembly;

FIG. 7 is a perspective view of two molded panels joined together toform a clam shell assembly;

FIG. 8 is an exploded view of the clam shell assembly illustrated inFIG. 7.

FIG. 9 is a rear perspective view of the composite body assembly;

FIG. 10 is a front perspective view of the composite body assembly;

FIG. 11 is front perspective view of the composite body assembly, a browand a fascia of the golf car;

FIG. 12 is a rear perspective view of the composite body assembly, browand fascia shown in FIG. 11;

FIG. 13 is an exploded view of the composite body assembly, brow andfascia shown in FIGS. 11-12;

FIG. 14 is an exploded view of a front decorative body panel of the golfcar;

FIG. 15 is a perspective view of the composite body assembly anddecorative body panels of the golf car shown in FIG. 1;

FIG. 16 is a rear elevational view of the composite body assembly andrear decorative body panel shown in FIG. 15; and

FIG. 17 is a front elevational view of the composite body assembly andfront decorative body panel shown in FIG. 15.

DETAILED DESCRIPTION

Referring now to the drawings in detail, wherein like numbers are usedto indicate like elements throughout, there is shown in FIGS. 1-17 apresently preferred embodiment of a vehicle 10, preferably a golf car 10or a utility vehicle 10. The vehicle 10 includes a frame assembly orframe 12 (FIG. 2), a body 14, front wheels 16 a and rear wheels 16 b.The vehicle 10 preferably further includes a canopy 17, canopy supports18, a seat 19, a seatback 21, armrests 22, a steering wheel 23, afloorboard panel 24, side panels 26, a structural accessory mount (SAM)25 including golf bag support ties 27, and a front bumper 28.

The frame assembly or frame 12, best shown in FIG. 2, provides supportand structural stability to the vehicle 10. The frame 12 also providesimpact resistance to certain areas of the vehicle 10, as discussedbelow. The frame 12, as shown in FIG. 2, includes two includes twolongitudinally-extending, laterally spaced-apart rails 31 and at leastone crossbeam 34 extending between and connecting the two rails 31.Preferably, the frame 12 also includes a dashboard support bar 32connected with the rails 31, a rear frame structure 36 and rear bodysupports 38.

The two elongated frame rails 31, best shown in FIG. 3, extend generallylongitudinally with respect to the vehicle 10 and are spaced apart atransverse distance X such that each frame rail 31 extends along andsupports outer side portions of the vehicle 10. The frame rails 31 curveinwardly toward the front 10 a of the vehicle 10, thereby decreasing thedistance between the two frame rails 31 at the front of the vehicle to atransverse distance Y and providing space outwardly of the forwardportions of the frame rails for the front wheels 16 a (FIG. 2). Theforward projecting ends 31 a of the frame rails 31 provide support for asteering and suspension assembly 33 (FIG. 2). The steering andsuspension assembly 33 is a unitary modular assembly mounted to theforward projecting ends 31 a of the frame rails 31, and the front wheels16 a are then mounted to the steering and suspension assembly 33.Rearward projecting ends 31 b of the frame rails 31 are spaced thetransverse distance X apart and are upwardly curved to provide space forthe rear wheels 16 b (FIG. 2). As best shown in FIG. 3, a pair ofsupport brackets 39 and two pairs of mounting brackets 41 a, 41 b areattached (e.g., welded, bolted, etc.) to rear portions of the framerails 31 to provide attachment surfaces and/or support for other vehiclecomponents. More specifically, the support brackets 39 are laterallyspaced-apart and are each fixed to an upper curved portion of the rearprojecting end 31 b of a separate one of the two frame rails 31. Thesupport brackets 39 each provide generally flat attachment surface forsecuring one of the two rear body supports 38 to the frame 12. Further,a first pair of mounting brackets 41 a each extend downwardly a centralportion of a separate one of the frame rails 31 and a pair of rearmounting brackets 41 b extend downwardly from the rear ends 31 b of theframe rails 31. The mounting brackets 41 a, 41 b are configured toconnect a pair of leaf springs 42 to the frame 12, as described below.

A support structure 37 (FIG. 3) for providing structural support to thedashboard support bar 32 is fixedly attached to the inwardly curvedportions of the forward projecting ends 31 a of the frame rails 31. Thesupport structure 37 includes two generally triangular side wallsections 37 a that are bolted or otherwise fixed to the inwardly curvedportions of the frame rails 31 and a generally rectangular central wallsection 37 b that spans the transverse distance Y between the forwardprojecting ends 31 a to centrally join inward facing edges of thetriangular plates 37 a. The support structure 37 primarily functionsboth to provide structural support to the dashboard support bar 32, andthus also to the steering column 70 connected thereto as discussedbelow, and to join together the forward projecting ends 31 a of theframe rails 31. Preferably, the support structure 37 is of one-piececonstruction, with the three wall sections 37 a and 37 b beingintegrally formed, but may alternatively be formed of separate piecesconnected together by any appropriate means (e.g., welding, rivets,etc.).

The dashboard support bar 32, best shown in FIG. 3, is disposed avertical distance above the frame rails 31, supported by the supportstructure 37. The dashboard support bar 32 is bolted or otherwise fixedto the support structure 37. The dashboard support bar 32 is generallyU-shaped with a substantially horizontal straight portion 32 a extendingtransversely from one side of the vehicle 10 to the other side and twocurved portions 32 b extending downwardly relative to the straightportion 32 a. As shown in FIG. 3, the curved portions 32 b are curvedsubstantially perpendicularly relative to the straight portion 32 a.Preferably, the dashboard support bar 32 is formed from a tubular bar,but may be formed of a solid bar or any other structural element.

The crossbeam 34, as best illustrated in FIG. 3, is connected with eachof the frame rails 31 by any appropriate means (e.g., rivets, bolts,weldment material, etc.). The crossbeam 34 is positioned substantiallyhorizontally, is generally shaped like an I-beam and extendssubstantially perpendicularly to the frame rails 31. The crossbeam 34provides support to a central portion of the vehicle 10 and serves tojoin a central portion of each frame rail 31 to a corresponding portionof the other rail 31. The crossbeam 34 extends the entire transversedistance X between the central portion of the frame rails 31. Thecrossbeam 34 includes upper and lower plate sections 34 a, 34 b,respectively, that each have opposing ends which extend transverselyover and are attached to an upper and lower surfaces of the frame rails31, respectively, so as to connect the crossbeam 34 to the rails 31. Thecrossbeam upper plate section 34 a also functions as a locater or guideto assist in correctly positioning sections of the vehicle body 14 ontothe frame 12, as described below.

The rear frame structure 36, as best illustrated FIG. 3, is attached tothe rearward projecting ends 31 b of the frame rails 31 by anyappropriate means (e.g., by threaded fasteners, welding, etc.). The rearframe structure 36 has forward facing apertures 36 a that mate with therearward projecting ends 31 b of the frame rails 31. The rear framestructure 36 has a substantially rectangular recessed portion 36 bintegrally formed with a rear curved portion 36 c. The rear framestructure 36, particularly the rectangular recessed portion 36 b, servesas an attachment surface for various vehicle components and sections ofthe vehicle body 14. The rear frame structure 36 also provides impactresistance to the vehicle 10 in the incidence of a rear collision. Therear curved portion 36 c includes a rearward-facing flat surface thatextends a transverse distance beyond each side of the recessedrectangular portion 36 a, thereby providing additional protection fromimpact.

The rearward extending ends 31 b of the frame rails 31 support a rearsuspension assembly 40 which includes leaf springs 42, as shown in FIG.2. The two pairs of mounting brackets 41 a, 41 b provide attachmentsurfaces for the leaf springs 42, which extend generally longitudinallywith respect to the vehicle 10 from the front brackets 41 a locatedcentrally on the frame rails 31 to the rear brackets 41 b locatedproximal the rear ends of the rails 31 b. The leaf springs 42 support arear axle 44, and the rear axle 44 supports the rear wheels 16 b, amotor 46 and associated motor components. As such, the motor 46 anddrive components, which may include an electric motor 47 a having agearbox 47 b (see FIG. 2) or an internal combustion engine 48 a with atransmission 48 b (see FIG. 5), are located substantially centrallybetween the rearward projecting ends 31 b of the frame rails 31.

The rear body supports 38, as best shown in FIG. 2, are secured to therearward projecting ends 31 b of the frame rails 31. The rear bodysupports 38 extend longitudinally along an upwardly curved portion ofthe frame rails 31 and vertically above the frame rails 31 to provideadditional height to the frame 12. The rear body supports 38 eachinclude generally parallel ribs 38 a extending from a curved surface 38b adjacent the curved portion of the frame rails 31 to a substantiallyflat and horizontal upper surface 38 c disposed a vertical distanceabove the curved surface 38 b and the frame rails 31. The upperhorizontal surface 38 c and a rear, generally vertical surface 38 d eachprovide an attachment surface for connecting other vehicle componentsand portions of the vehicle body 14, as described below.

The dashboard support bar 32, the support structure 37, the crossbeam34, the rear frame structure 36, the rear body supports 38, the supportbrackets 39 and the mounting brackets 41 a, 41 b are all connected withthe frame rails 31, as described above, in any conventional manner, suchas by weldment material or welding, threaded fasteners such as bolts orscrews, by rivets, and/or by any other appropriate means. The framerails 31, dashboard support bar 32 and crossbeam 34 may be extruded orformed from cut lengths of commercially available tubes or bars, and maybe formed of aluminum, steel and/or another high strength metal orpolymer. The rear frame structure 36, the support structure 37, the rearbody supports 38 and the support brackets 39, and the mounting brackets41 a, 41 b may each be fabricated of a molded polymeric material or of acast, stamped, forged, and/or machined metallic material. In a preferredform of the invention, the frame rails 31 and crossbeam 34 are formed ofextruded aluminum, the dashboard support bar 32 formed of extrudedsteel, the support structure 37 is formed of steel, and the rear framestructure 36 and rear body supports 38 are formed of acompression-molded, fiber-reinforced polymer. Specifically, the rearframe structure 36 is preferably formed of 30% glass fiber reinforcedpolypropylene homopolymer, and the rear body supports 38 are preferablyformed of a 30% glass filled, chemically coupled impact polypropylenecopolymer, POLFORT® FPP 1606 (available from A. Schulman, Inc.).

A composite body assembly 58 (FIGS. 4 and 6) is mounted to the frame 12,and when connected with the frame 12, provides a high strength frame andbody assembly 35. The composite body assembly 58 is configured toincrease the rigidity of the frame 12 so as to add strength and rigidityto the vehicle 10. In addition, the composite body assembly 58 andprovides support and attachment surfaces for many of the vehiclecomponents, including a battery or fuel supply bucket 66, support braces68 for the SAM 25, and other components as discussed below. In apreferred form of the present invention, the composite body assembly 58is formed of a 30% glass fiber reinforced polypropylene copolymer.

As shown in FIGS. 4 and 6, the composite body assembly 58 includes afront body section 60 a, preferably formed as a clam shell assembly 62(as described in greater detail below), and a rear body section 60 bthat is preferably formed as a one-piece housing or shell 64 (discussedbelow). The front clam shell assembly 62 and the rear body shell 64 maybe independently attachable to the frame 12 and need not be connectedtogether. The clam shell assembly 62 provides support to front andcentral portions of the vehicle 10. The front clam shell assembly 62 isa generally box-like frame that curves upwardly toward the front of thevehicle 10, as best shown in FIG. 4, to provide a pair oflaterally-spaced front wheel wells 71 a for the front wheels 16 a. Theclam shell assembly 62 extends generally longitudinally rearwardly froma front edge 65, spaced vertically above the front axle and steering andsuspension assembly 33 when connected with the frame 12, to a rear edge67 that is generally proximal to the support brackets 41 a (FIG. 3) onthe frame rails 31, and thus located forwardly of the rear wheels 16 b.Further, the clam shell assembly 62 provides a dashboard 62 a and afloorboard support 62 b of the vehicle 10.

More specifically, the dashboard 62 a is integrally formed with thefloorboard support 62 b via a substantially vertical portion 62 c of theclam shell assembly 62, and is disposed a vertical distance above thefloorboard 62 b following the structure set forth by the frame 12. Uppersurfaces of both the dashboard 62 a and the floorboard support 62 b aresubstantially horizontal and extend transversely on each side of thevehicle 10 beyond the frame 12. The dashboard portion 62 a of the clamshell assembly 62 is attached to the dashboard support bar 32, and thefloorboard support portion 62 b is supported by the crossbeam 34 and isattached to the frame rails 31. The dashboard 62 a further includesslots and/or surfaces 62 e for attaching a brow 102 to the front of thevehicle 10 (FIGS. 11-15 and 17), which is described in detail below. Thefloorboard support 62 b includes a raised edge 62 d that extendsvertically upwardly relative to the floorboard support 62 b. The raisededge 62 d is curved to match a peripheral shape of the battery or fuelsupply bucket 66 to define a secure location for the battery or fuelsupply bucket 66. As shown in FIGS. 4 and 6, the clam shell assembly 62is preferably attached to the frame rails 31 and the dash support bar32.

As mentioned above, the rear body section 60 b includes a generallyshell-like body or shell 64 having an open lower end 57 and at leastpartially bounding an interior chamber 59. The rear body shell 64 thatextends longitudinally between a front edge 75 and a rear edge 77, thefront edge being located adjacent the clam shell rear edge 67 and therear edge 77 being located behind the rear wheels 16 b when the bodysection is disposed on the frame 12. The rear body shell 64 curvesupwardly, following the structure of the frame rails 31, to provide apair of laterally-spaced wheel wells 71 b for the rear wheels 16 b. Therear body shell 64 has an upper portion 64 a and a lower portion 64 b,each having a periphery. The periphery of the upper portion 64 a isrecessed inwardly relative to that of the lower portion 64 b. As shownin FIGS. 4 and 6, the rear body shell 64 is bolted or otherwise fixed tothe rear body supports 38 and the rear frame structure 36. The upperportion 64 a further defines an upper, substantially horizontalattachment surface 80 for attaching the SAM support braces 68 to thevehicle 10.

FIGS. 7 and 8 illustrate the clam shell assembly 62 in greater detail.As shown in FIGS. 7 and 8, the clam shell assembly 62 includes an upperpanel 61 and a lower panel 63. FIG. 6 illustrates the clam shellassembly 62 with the upper and lower panels 61 and 63 joined together.In a preferred form of the invention, the upper and lower panels 61 and63 are vibrationally welded together to form the clam shell assembly 62.As shown in FIG. 7, the clam shell assembly 62 provides clearanceopenings and attachment surfaces for several vehicle components,including a first clearance aperture 74 a for the steering columnassembly 70, a second aperture 76 a and attachment surface 76 b for amodular pedal group assembly (not shown) and a third aperture 78 a andattachment surface 78 b for the battery or fuel supply bucket 66. Thedashboard portion 62 a of the clam shell assembly 62 is primarily formedfrom the upper panel 61. The dashboard portion 62 a includesupwardly-opening molded storage compartments 79 for passengeraccessories and personal items, including storage space for wallets,purses, gym bags, car keys, and the like. The storage compartments 79are integrally molded into the dashboard portion 62 a of the clam shellassembly 62, and more particularly, are molded into a front, upperportion of the upper panel 61.

FIG. 8 shows an exploded view of the front clam shell assembly 62. Asillustrated in FIG. 8, two panels 61, 63 formed of fiber-reinforcedpolymer are molded (e.g., compression molded) to form a series oflongitudinally extending channels 63 a with respect to the vehicle 10,such that when they are joined together, the joined panels 61, 63 form aplurality of longitudinal cavities between the panels 61, 63. Thelongitudinal cavities define open air spaces between the panels 61, 63,and such cavities provide strength and toughness to the clam shellassembly 62. The cavities are preferably filled with air, but thecavities may instead be filled with fluid or material to change theimpact resistance, strength and toughness of the clam shell assembly 62.For example, the cavities may be filled with an impact absorbing orresilient material.

The lower panel 63 further includes a plurality of flat surfaces 69 thatmate with opposed surfaces on the upper panel 61, as shown in FIG. 8. Asmentioned above, the lower panel 63 includes a recessed portion with asupport or attachment surface 76 b for housing an accelerator pedaland/or a brake pedal, preferably a modular pedal group assemblyincluding the pedals (not shown), such that the front body section 60 ais configured to support the one or more pedals. The lower panel 63further provides side supports 73 to the vehicle 10 to support andprovide attachment surfaces for the side panels 26 (FIG. 1). The lowerpanel 63 also provides one or more attachment surfaces 72 for mountingthe entire clam shell assembly 62 to the frame 12, and particularly, tothe frame rails 31 and the dashboard support bar 32. Alternatively, theupper panel 61 may include one or more attachment surfaces for attachingthe clam shell assembly 62 to the frame 12 in addition to or instead ofthe lower panel attachment surfaces 72.

FIGS. 9 and 10 illustrate the rear body shell 64 disposed adjacent tothe front clam shell assembly 62 so as to form the composite bodyassembly 58. As mentioned above, the front clam shell assembly 62 andrear body shell 64 are preferably not connected together prior to beingmounted to the frame 12. The rear body shell 64 is preferably formed ofone-piece construction, i.e., a single or unitary, integral piece. Theillustrated embodiment shows the rear body shell 64 as a unitarycompression-molded piece comprised of fiber-reinforced polymer. In apreferred form of the invention, the fiber-reinforced polymer is afiberglass-reinforced polypropylene.

When the rear body section 60 b is disposed on the frame 12, the shell64 is positioned such that the rear axle 44, the motor 46 and associateddrive system components, i.e., either electric motor 47 a and gearbox 47b or IC engine 48 a and transmission 48 b, are at least partiallydisposed within the interior chamber 59 of the rear body section 60 b.The rear body shell 64 also provides an attachment surface 80 for thesupport braces 68 and SAM 25. The rear body shell 64 may also provide arear bumper 82 positioned to absorb impact, as shown in FIG. 9. Further,the rear body shell 64, as illustrated in FIG. 10, also includes a golfbag support or well 84, which is an integral recessed portion of therear body shell 64, and has a base and one or more walls. The golf bagsupport or well 84 may be used for housing, supporting and transportinggolf bags. The rear body shell 64 therefore has high strength andstructural stability for supporting the weight of two or more golf bagsand high impact resistance to serve as the rear bumper 82 in the eventof a rear collision. As illustrated in FIG. 9, the rear body shell 64also includes an access opening 86 positioned to facilitate access tothe motor 46 and/or drive components 48 (FIGS. 2 and 4) for maintenanceand repair, and a removable panel 87 configured to obstruct (i.e.,cover) the access opening 86 when disposed on the rear body section 60b.

FIGS. 11, 12 and 13 illustrate a brow 102 and a fascia 104 bolted orotherwise fixedly mounted to a front portion of the vehicle 10. The brow102 is preferably formed of an injection molded, fiber-reinforced,polymer and secured to the upper panel 61 of the clam shell assembly 62.In a preferred form of the invention, the brow 102 is constructed of a20% CaCO₃-filled, UV stable polypropylene copolymer, POLYFORT® FPP 3708U(available from A. Schulman, Inc.). The brow 102 includes a plurality ofspaced apart, substantially parallel ribs 102 a that extend from anuppermost arch 102 b to a lowermost arch 102 c, the ribs 102 a definingtherebetween a series of channels 102 d. A front decorative body panel106 (FIGS. 14, 15 and 17) is formed to fit over the brow 102 to provideaesthetic appeal to the vehicle 10. The channels 102 d define cavitiesformed between the front decorative body panel 106 and the brow 102.Similar to the cavities defined between the upper and lower panels 61,63 of the clam shell assembly 62 described above, these cavities may beopen air spaces or may alternatively be filled with fluid or material,such as a resilient, impact-absorbing material. The cavities thereforeprovide structural support to the front 10 a of the vehicle 10.

As shown in FIGS. 11, 12 and 13, the fascia 104 is bolted or otherwisefixed to the brow 102 and extends forwardly from the brow 102. Thefascia 104 has a curved shape with one relatively straight portion 104 aand two curved portions 104 b that extend rearward relative to thestraight portion 104 a and curve substantially perpendicularly to thestraight portion 104 a. The fascia resembles a typical vehicle bumperand extends transversely, spanning the width of the front of the vehicle10. Referring particularly to FIG. 13, the fascia 104 includes aplurality of slots 104 d engageable by tabs 106 a of the body panel 106,as discussed below, and the curved portions 104 b include tabs 104 cthat mate with the opposing slots 62 e in the clam shell assembly 62.The fascia 104 has a periphery 105, and the front decorative body panel106 (FIGS. 14, 15 and 17) is recessed inwardly from the periphery 105 soas to be protected by the fascia 104 from damage. However, the fascia104 need not be constructed of a high impact resistant material becauseone or more additional bumpers, such as bumper 28 shown in FIG. 1, maybe disposed beneath the fascia 104 and in front of the steering andsuspension assembly 33 to offer additional protection to the vehicle 10in the event of a head-on collision.

FIG. 13 shows a close-up of the assembly of the brow 102 to thedashboard 62 a and assembly of the fascia 104 to the brow 102 and clamshell assembly 62. Specifically, the brow 102 and fascia 104 areattachable to the upper panel 61 of the clam shell assembly 62. As bestshown in FIGS. 12 and 13, the brow 102 also serves as a covering and/orsplash guard for the dashboard 62 a, thereby providing coverage andprotection for items stowed in the storage compartments 79.

Decorative body panels 106 and 108 are added to the vehicle 10 both toprovide an aesthetically-pleasing exterior and to enclose certainvehicle components, as discussed below. The decorative body panels 106and 108 are preferably each formed of a single, molded panel. In apreferred form of the invention, the decorative body panels 106 and 108are constructed of super-gloss molding alloy from the SURLYN® REFLECTIONseries (e.g., SURSG201), available from DuPont Company.

As illustrated in FIGS. 14, 15 and 17, the front decorative body panel106 is rounded to match and cover the underlying structure of the brow102. The front decorative body panel may include a company logo orvehicle identifier 107, as shown in FIGS. 14, 15 and 17. FIG. 14illustrates the assembly of the front decorative body panel 106 to thebrow 102. The front decorative body panel 106 includes a plurality ofspaced apart tabs 106 a that extend downwardly from a bottom edge of thefront decorative body panel 106. The tabs 106 a are engageable with theslots 104 d of the fascia 104 and slots 62 f formed in the dashboard 62a of clam shell assembly 62. The front decorative body panel 106 isassembled by aligning and inserting the tabs 106 a into correspondingslots 104 d or 62 f, and securing the front decorative body panel 106 tothe brow 102 by bolting or otherwise securing an arch 103 over an upperedge of the front decorative body panel 106 to the brow 102 and/or clamshell assembly 62.

The rear decorative body panel 108 is illustrated in FIGS. 15 and 16.The rear decorative body panel 108 is a single panel, i.e., of one-piececonstruction, and basically includes a front wall section 109, twosidewall sections 110A, 110B, and a transverse member or bar 111. Thetransverse bar 111 is spaced rearwardly of the front wall section 109and extends between and connects the sidewall sections 110A, 110B, suchthat the panel 108 has a substantially rigid structure. Preferably, therear body panel 108 is constructed of a injection-molded, high glosspolymer, but may alternatively be compression-molded or otherwise formedand constructed of any other appropriate materials.

Further, the rear decorative body panel 108 has an outer periphery 118and is adapted to fit onto a rear portion of the clam shell assembly 62and the rear body section lower portion 64 b. When disposed on the shellassembly 62 and rear body shell 64, the body panel 108 is disposed aboutor encloses the battery or fuel supply bucket 66 and the rear compositebody upper portion 64 a (FIGS. 9 and 10). As such, the rear body panel58 forms part of the structure of the composite body assembly 58, asopposed to being solely or primarily a decorative component. The reardecorative body panel 108 includes openings 112 and 113 designed to fitabout portions of the battery or fuel supply bucket 66 and the rearcomposite body upper portion 64 a, respectively, the transverse bar 111defining and separating the two openings 112 and 113.

As illustrated in FIGS. 1, 15 and 16, the lower portion 64 b of the rearbody shell 64 is visible when the rear decorative body panel 108 isdisposed on the remainder of the composite body assembly 58. The rearcomposite body lower portion 64 b has a periphery 114 that extends or isspaced outwardly on all sides relative to the periphery 118 of the reardecorative body panel 108, so as to protect the rear panel 108 fromimpact, abrasions or other undesired contact. In other words, as thedecorative body panel 108 is inwardly recessed from the rear compositebody lower portion 64 b, another vehicle or an obstacle (e.g., a tree, afence post, etc.) will first contact the rear body section 60 b during acollision, such that impact with the body panel 108 is substantiallyprevented.

1-16. (canceled)
 17. A golf car, comprising: a high-strength moldedcomposite body assembly, formed from at least one moldedfiber-reinforced polymer panel, the composite body assembly having aperiphery; a plurality of wheels supporting the body for movement alongthe ground; and at least one decorative body panel disposed on thecomposite body assembly, the body panel being recessed inwardly relativeto the periphery of the composite body assembly such that the bodyassembly extends outwardly of the decorative body panel so as to preventimpact with the body panel.
 18. The golf car as set forth in claim 17,further comprising a frame to which the wheels and the composite bodyassembly are attached, the frame including two longitudinally extending,laterally spaced-apart rails and at least one crossbeam extendinglaterally between and connecting the two frame rails. 19-20. (canceled)21. The golf car as set forth in claim 18, wherein the frame furtherincludes a dashboard support bar connected with the two rails andconfigured to support a dashboard of the golf car.
 22. The golf car asset forth in claim 17, wherein the composite body assembly is formed ofat least one compression molded panel.
 23. The golf car as set forth inclaim 17, wherein the composite body assembly includes a front bodysection, the front body section including at least two moldedfiber-reinforced polymer panels connected together so as to form a clamshell assembly, and a rear body section formed of a fiber-reinforcedpolymer.
 24. The golf car as set forth in claim 23, wherein the clamshell assembly and the rear composite body are each independentlyattachable to a frame. 25-30. (canceled)
 31. The golf car as set forthin claim 17, wherein the decorative body panels are formed of ahigh-gloss polymer. 32-41. (canceled)
 42. A method for manufacturing avehicle comprising the steps of: providing a frame; connecting twomolded fiber-reinforced polymer panels to form a clam shell assembly;mounting the clam shell assembly to a front portion of the frame;mounting a rear body section to a rear portion of the frame, the rearbody section being formed of a fiber-reinforced polymer, the clam shellassembly, the rear body section and the frame forming a substantiallyrigid high-strength frame and body assembly; and connecting at least onedecorative body panel to the frame and body assembly, wherein the atleast one decorative body panel is are recessed inward relative to aperiphery of the frame and body assembly such that the frame and bodyassembly protects the decorative body panel from damage. 43-61.(canceled)
 62. The golf car as set forth in claim 17, wherein: thecomposite body assembly includes a front body section and a rear bodysection, the rear body section including a shell with an open lower end,the shell at least partially bounding an interior chamber; and the atleast one decorative panel includes a rear decorative panel disposedabout a portion of the rear body section of the composite body assembly.63. The golf car as set forth in claim 62 further comprising a motor andassociated drive system components connected with the frame and at leastpartially disposed within the interior chamber of the rear body section.64. The golf car as set forth in claim 17 wherein: the composite bodyassembly includes a rear body section having an upper portion and alower portion each having a periphery, the periphery of the upperportion being recessed inwardly relative to the lower portion; the atleast one decorative body panel includes a rear decorative body panelconfigured to fit about portions of the upper portion of the rear bodysection.
 65. The golf car as set forth in claim 64 wherein the lowerportion of the rear body section is visible when the rear decorativebody panel is disposed on the composite body assembly.
 66. The golf caras set forth in claim 64 wherein the rear decorative body panel includesa front wall section and two sidewall sections, the decorative bodypanel enclosing the upper portion of the composite body rear sectionsuch that the rear body section upper portion is disposed generallybetween the front wall section and two side wall sections.
 67. The golfcar as set forth in claim 64 further comprising one of a battery and afuel supply, the rear decorative body panel enclosing the one of thebattery and the fuel supply.
 68. The golf car as set forth in claim 17wherein the composite body assembly includes front and rear bodysections and the at least one decorative body panel includes a frontdecorative body panel connected with the composite body front section.69. The golf car as set forth in claim 68 wherein the composite bodyassembly includes a brow connected with the front body section and afascia connected with and extending forwardly from the brow, the frontdecorative body panel being mounted to the brow.
 70. The golf car as setforth in claim 69 wherein the front decorative body panel is rounded tomatch and cover the underlying brow.
 71. A golf car comprising: ahigh-strength molded composite body assembly formed from at least onemolded fiber-reinforced polymer panel, the composite body assemblyincluding a front body section with a periphery and a rear body sectionwith a periphery; a front decorative body panel disposed on the frontbody section of the composite body assembly, the front decorative bodypanel being recessed inwardly relative to the periphery of the frontbody section such that a portion of the front body section extendsoutwardly of the front decorative body panel so as to prevent impactwith the front decorative panel; and a rear decorative body paneldisposed on the rear body section of the composite body assembly, therear decorative body panel being recessed inwardly relative to theperiphery of the rear body section such that the rear body sectionextends outwardly of the rear decorative body panel so as to preventimpact with the rear decorative panel.